Showing papers on "Honing published in 2010"

Tribological behavior of micro structured surfaces for micro forming tools

Abstract: Mechanical micro machining processes, like milling and grinding are appropriate technologies for the flexible production of precise molds with complex shapes for metal forming processes. In most cases machining strategies are orientated towards form accuracy of the desired forming tool only. Thus, the generation of tribologically advantageous surfaces is often carried out in subsequent machining steps like honing. In micro scale the subsequent treatment of complex surfaces is very difficult. For that reason it is desirable to create the shape and a suitable surface texture with one tool in one step. This paper is focusing on the comparison of the tribological behavior of polished surfaces with structured surfaces machined by micro milling and micro grinding processes. Micro milling tools and grinding pins with ballend shape are used to create micro structured surfaces. The machining strategy (tool path and line pitch) was varied for both tool types in the same manner. The experiments were carried out on hardened cold working steel using tungsten carbide micro cutters with TiAlN coating and micro grinding pins with an abrasive diamond layer. White light interferometry was used to characterize the machined surfaces and determine the surface parameters. Moreover, a strip drawing test was set up to investigate the tribological behavior of the system consisting of the machined surfaces and thin sheet metals. The results of the strip drawing test suggest a relationship between micro structure and tribological behavior. Finally, the dependencies between machining technology, surface parameters and tribological behavior will be discussed.

Investigations on precision finishing of helical gears by electrochemical honing process

Abstract: This paper presents the findings of an investigation into the effects of finishing time, electrolyte-related parameters (i.e. electrolyte temperature, composition, and concentration), voltage, and rotating speed of the workpiece on the improvement of surface quality of helical gear teeth finished by the electrochemical honing (ECH) process. Percentage improvement in average surface roughness PIRa and maximum surface roughness PIRtm, three-dimensional plots of the finished surface texture, and microhardness have been used as the measures of ECH process performance. The effects of finishing time, electrolyte temperature, and electrolyte composition have been studied through pilot experiments by varying one variable at a time, while the effects of voltage, rotating speed of the workpiece gear, and electrolyte concentration have been studied during the main experiments designed using the Box–Behnken response surface methodology approach. Scanning electron microscopy and optical profilometry before and...

A study on the influence of bond material on honing engine cylinder bores with coated diamond stones

Abstract: A consistent increase in demand for special tools designed to enhance an efficient honing of engine cylinder bores is observed. Metallic Bonded Diamond Stones (Dia-M) are more and more used for their wear resistance and their high tool life. However, the hardness of this Metallic Bond leads to the degradation of the honed surface aspect by the formation of smudgy grooves edges (blechmantel). This torn and folded metal affects the required functional performances of the cylinder bore. In this study, two new diamond coated abrasive stones with Vitrified and Resinoid Bonds (respectively Dia-V and Dia-R) are tested and compared to the Dia-M sticks. The influences of bond material on the honing reliability are studied in terms of honed surface aspect, material removal rate and wear properties. Results reveal that the stiffness and the openness structure of the Resinoid Bond leads to a better trade off between surface aspect and tool life.

A method for profiling a honing tool for honing a toothing of a workpiece

Abstract: The invention makes it possible, in a simple and cost-effective manner, to produce a honing tool (3) which ensures an optimized work result with respect to manufacturing precision and which also allows the shaping of the honing tool to be varied with the largest possible design freedom. For this purpose, according to the invention: a) a honing tool (3) is provided, the profile of which is unfinished; b) the honing tool (3) having the unfinished profile is chucked in a holder (2) of a honing machine (1) which is intended to hold the honing tool (3) while a workpiece is honed; c) a profiling tool (8) is chucked in the workpiece spindle (4) of the honing machine (1), and d) the profiling tool (8) and the honing tool (3) are oriented and moved relative to one another such that the profiling tool (3) engages with the honing tool (3) and on the honing tool (3) replicates the toothing profile (7) required for honing the toothing of the workpiece.

Long-stroke pneumatic hydraulic cylinder body processing method

Abstract: The invention discloses a long-stroke pneumatic hydraulic cylinder body which includes an outer cylinder body and an inner cylinder body which are made of circular steel pipes; the middle part of the outer cylinder body has an oil through which is communicated with the hydraulic cavity of the pneumatic cylinder body; the pneumatic hydraulic cylinder body is characterized in that the inner wall surfaces of the outer cylinder body and the inner cylinder body are respectively provided with grids which can store oil and lead the outer cylinder body and the inner cylinder body to keep long-time lubrication, reduce wear and prolong service life although the grids are tiny. The processing method of the outer cylinder body is as follows: a. fetching a seamless precision steel pipe with the specification of inner hole diameter of 15 mm, and length of 400 mm; b. using a lathe for turning both ends flat, and heat treatment quenching and tempering stereotype; c. using honing roughing, grinding the inner hole diameter up to be 15 mm; d. using a mandrel for sheathing the inner hole, using an excircle grinder for grinding the excircle, requesting concentricity; e. usinga CNC lathe for cutting the oil through; f. carbonation treatment: enabling the depth up to be more than 0.05 mm; and g. adopting honing finishing so as to lead the finish to be about 0.05 mm and thestraightness to be 400/0.01 mm, and the roundness to be controlled as 0.002 mm, and lead the inner wall surface of the steel pipe to form small grids.

Python Regius (Ball Python) shed skin: Biomimetic analogue for function-targeted design of tribo-surfaces

Abstract: A major concern in designing tribo-systems is to minimize friction, save energy, and to reduce wear. Satisfying these requirements depends on the integrity of the rubbing surface and its suitability to sliding conditions. As such, designers currently focus on constructing surfaces that are an integral part of the function of the tribo-system. Inspirations for such constructs come from studying natural systems and from implementing natural design rules. One species that may serve as an analogue for design is the Ball python. This is because such a creature while depending on legless locomotion when sliding against various surfaces, many of which are deemed tribologically hostile, doesn't sustain much damage. Resistance to damage in this case originates from surface design features. As such, studying these features and how do they contribute to the control of friction and wear is very attractive for design purposes. In this work we apply a multi scale surface characterization approach to study surface design features of the Python regius that are beneficial to design high quality lubricating surfaces (such as those obtained through plateau honing). To this end, we studied topographical features by SEM and through White Light Interferrometery (WLI). We further probe the roughness of the surface on multi scale and as a function of location within the body. The results are used to draw a comparison to metrological features of commercial cylinder liners obtained by plateau honing.

Cutting tip replacement type rotary tool

Abstract: An indexable milling cutter is provided which is capable of achieving a reduction in cutting resistance while maintaining chipping resistance of a main cutting edge formed in an insert and suitable for highly efficient high-feed processing. It is an indexable milling cutter including an insert attached thereto which can be attached to and detached from a cutter body and which has a polygonal plate or round shape as seen in a plan view. In this insert, a negative honing and a land are provided on a rake face of a main cutting edge, and a rounded corner cutting edge is formed at a corner portion. Moreover, it is an indexable milling cutter which achieves a reduction in cutting resistance while maintaining the chipping resistance of the main cutting edge by making the main cutting edge of the insert have a lowermost point with respect to a rotation axis direction of the cutter body when the insert is attached to the cutter body and by forming the width of the negative honing or the widths of the negative honing and the land so as to gradually increase from the lowermost point toward an outer periphery side direction with respect to the rotation axis direction of the cutter body.

Experimental selection of special geometry cutting tool for minimal tool wear

Abstract: A major problem in achieving high production rates in metal cutting industry is Tool Wear. Prolonged tool life has gained significance with the discovery of materials like hard steels, and the urge to maintain tighter geometric tolerances and improved surface finish. Strengthening of the edge and prevention of its deterioration is achieved by the several edge geometries that have been proposed; the most prominent being chamfered tools and honed tools. But, the investigation of the effect of different chamfer angles and honed radii on the machining parameters and tool life is not much done. The present work is an attempt to study the influence of these variables on tool wear. EN-8 steel with sharp tool and different chamfered and honed tools has been machined and experimental investigations have been carried out. Variations in cutting forces, tool wear, and thus tool life, have been observed for all the cases. Inferences drawn are validated and the performance of the tools for workpieces with different hardness is assessed by machining EN-9 under similar cutting conditions using similar tools as in the previous case. Results obtained in both the cases are analogous, thus validating the conclusions made. The work can be extended by considering more values chamfer angle and honing radii.

Production process adopting silicon rubber gypsum precision casting and used for hydraulic bending moment guide wheel

Abstract: A production process adopting silicon rubber gypsum precision casting and used for a hydraulic bending moment guide wheel comprises the following steps: designing and producing a silicon rubber metal mould; producing a combined silicon rubber mould; producing an integral gypsum core; roasting the gypsum core; carrying out gypsum metal type combination and then casting on a low-pressure casting machine; and carrying out casting cleaning and polishing, heat treatment and liquid honing. Due to the adoption of a metal-shell integral-gypsum-core composite casting process, the surface roughness Ra (an unprocessed surface) of the cast guide wheel is less than 6.3 microns, and the size precision of the cast surface is 0.5 mm more or less. Due to the adoption of a gypsum metal type low pressure casting process, the mechanical property of the casting is far better than that of a casting obtained by means of rubber sand casting. The above two improvements satisfies the requirements of the use of a hydraulic bending moment guide wheel casting in the aspects of surface, size precision and performance.

Precise high-speed digital-controlled system of honing machine

Abstract: The invention discloses a precise high-speed digital-controlled system of honing machine, comprising an ARM microprocessor, a memory, a D/A conversion circuit, a pulse generation circuit, an orthogonal pulse counter, a multi-channel A/D conversion circuit, an LCD display and a control panel; wherein the D/A conversion circuit is connected with a voltage/current conversion circuit at output end; input end of the orthogonal pulse counter is respectively connected with difference/voltage conversion circuits; input end of the multi-channel A/D conversion circuit is connected with an amplificationcircuit; further, one input/output port of the ARM microprocessor is connected with an interface circuit. This invention adopts human-computer interaction interface, realizes simple structure and convenient as well as visual operation, and achieves multifunctional controls as movement and rotation of main shaft of the honing machine, micro-step driving of two feed mechanisms, three-way non-linkage control of working table and online detection; further, this invention is complete in function, high in control precision, low in cost, and applicable to national mechanical manufacturing field.

Honing tool having mechanically controlled, hydraulic single or multiple expansion

Abstract: In the honing method, multiple individual machining processes lead to downtime due to the tool change. The novel honing tool enables a multiple honing machining process by means of one tool without a change in the machining center. Depending on the position of a mechanical control slide (9), one or more further tool cones (5) are intermittently individually impinged upon by a non-solid medium in a pressure line (10) by means of a feed (8) and thus controlled. Said system can be used especially advantageously in machining centers (MCs).

Development of a honing process for the combination machining of hardened axisymmetric parts

Abstract: This paper presents a novel concept to enhance the conventional combination machining ‘turning and grinding’ by a long-stroke honing process for finishing bores of axisymetric parts. Honing is the best choice when the surface integrity of tribologically highly-stressed parts is of vital importance. The presented approach reduces the required overall machining time when compared with that of the conventional machining sequence on separate machine tools, and also enhances the production accuracy through a single clamping setup. The fundamental details like tool design, infeed strategies and possible process-chains of the developed approach for honing on a combination machining center are explained. Experimental results of two different process-chains are analyzed: Firstly, the ‘turning-grinding-honing’ (TGH-chain), where honing is conducted after the grinding process; and secondly, the ‘turning-honing’ (TH-chain), where honing is applied directly after the rough turning. The experiments showed promising results for the applied position-controlled infeed strategy of the developed long-stroke honing process regarding the production efficiency.

Method for finishing borehole in workpiece in internal combustion engine, involves interconnecting no drilling operation between manufacturing of prepared borehole

Abstract: The method involves interconnecting no drilling operation between the manufacturing of the prepared borehole and the engine power honing operation. A degradation of 0.5 millimeter is generated under the use of a honing tool by the honing of the borehole relative to the diameter of the borehole during the engine power honing operation. The engine power honing operation is executed as honing operation such that a shifting of the bore axis takes place in the direction of the target position by the engine power honing operation. An independent claim is also included for a device for finishing a borehole in a workpiece, particularly for finishing a crankshaft bearing borehole in a cylinder crankcase of an internal combustion engine.

Data mining approach for selection of plateau honing parameters with dual objectives

Abstract: Surface topography of cylinder liners plays an important role in terms of functionality of the engine. The surface is finished by honing process in various stages namely rough, finish and finally plateau honing to have proper plateau portion (bearing area) at the top to resist wear and grooves at desired honing angle to retain lubrication during engine operation. Selection of parameters and their levels in plateau honing operations to achieve required surface topography is found to be very difficult. For the first time, data mining approach is used in this investigation to select significant honing parameters and their levels considering two important bearing area parameters namely core roughness depth (Rk) and material portion in the valley zone (Mr2) together. Data mining model was trained and tested using experimental data. The significant input plateau honing parameters have been identified and graphical representation of the decision tree has been also presented for easier understanding.

Improving the Precision of Gear Honing with External Honing Ring Using Diamond Dressing Gear

Abstract: The gear honing process is a widely used process for gear finishing after heat-treated, and may be divided into the variants “internal-tooth honing” and “external-tooth honing”. External- tooth honing is seldom used in gear finishing due to lower overlapping ratio and relatively low precision. But its process cost is much lower than internal-tooth honing and gear grinding. The paper puts forward a new method to improve the precision of external-tooth honing, i.e. honing ring is profiled by diamond dressing gears, which have the profile of the workpiece to be machined. Meshing and Tooth contact analysis of honing ring profiling has been considered. Meshing equation of profiling process and equation of honing ring tooth flank after profiling are obtained. Experiment testified that it is an applied method and has many advantages.

Main axle hydraulic pressure feeding mechanism for numerically controlled deep borehole honing machine

Abstract: The present invention discloses a hydraulic main shaft feed mechanism of a numerically controlled deep hole honing machine, which comprises a base seat, a main shaft, a main shaft motor and a honing head feed mechanism, wherein, the main shaft is arranged on the base seat, the main shaft motor drives the main shaft to rotate, the honing head feed mechanism is arranged on one end of the main shaft, and the other end of the main shaft is connected with a honing head mechanism. The output shaft of the main shaft motor is connected with the main shaft via a main shaft reduction gearbox, and the main shaft is of a hollow structure. The honing head feed mechanism includes a hydraulic oil cylinder connected with the base seat, on the feed end of which a feed rod component is fixed, and in the main shaft, the feed rod component is driven by the hydraulic oil cylinder to push a push rod connected with a honing head to axially and linearly move to-and-fro. The present invention applies a numerical control system to control feed and can realize feed of constant quantity and constant pressure via the hydraulic oil cylinder, and the accuracy and automation degree of feed is high.

Honing machine with multiple power-units and follow-up work station

Abstract: The invention relates to a honing machine provided with a plurality of power heads and a follow-up station platform A guide rail pedestal, a longitudinal rolling linear guide rail, a lower slipway, a transverse rolling linear guide rail, a middle slipway, a vertical rolling linear guide rail, and an elevating platform are arranged in a cutting flume from the bottom to top sequentially A cylinder provided with a hand-operated change air valve is arranged on the middle slipway and is connected with the elevating platform for clamping and releasing workpieces The lower slipway, the middle slipway, the elevating platform and each rolling linear guide rail are assembled together to form a set of the follow-up station platform which can move longitudinally, transversely and vertically A machine frame is fixedly provided with a motor, a speed-down belt pulley group and a plurality of the unit heads in parallel A belt pulley is arranged above a main shaft of each power head, and a corundum reamer or a channel brush is arranged below the main shaft of each power head The motor is electrically connected with an electric control box The speed-down belt pulley group is connected with the motor and each power head though belts A cutting fluid circulation system is arranged on a machine body The follow-up station platform of the oil-stone grinder can more freely align with a cutting tool after clamping a workpiece, the method has small labor intensity and advanced operation method The plurality of the power heads are driven by one motor so as to improve the honing precision and reduce the processing cost

Insert used for tip replacement type rotary tool for milling cutter

Abstract: PROBLEM TO BE SOLVED: To provide an insert attached to a tip replacement type rotary cutting tool for a milling cutter, which reduces cutting resistance while keeping the chipping resistance of the main cutting edge, and achieves highly efficient high-feed cutting. SOLUTION: The insert can be attached/detached to/from a rotary tool body, and has a polygonal flat plate shape in a plan view. In the insert, a negative honing and a land are provided on the rake face of the main cutting edge, and an R-shaped corner blade is formed at a corner portion. When the insert is attached to the rotary tool body, the main cutting edge of the insert defines the lowermost point in the rotation axis direction of the rotary tool body, and the width of the negative honing or the width between the negative honing and the land is formed so as to gradually increase from the lowermost point toward the outer peripheral side direction with respect to the rotation axis direction of the rotary tool body. COPYRIGHT: (C)2011,JPO&INPIT

Novel nylon base honing oilstone

Abstract: The utility model relates to a novel nylon base honing oilstone The scheme adopted by the utility model includes that the novel nylon base honing oilstone comprises a base plate and an abrasive stickinstalled on the base plate; the abrasive stick is formed by integrally casting a plastic seat positioned on the lower portion of the abrasive stick and honing oilstones inside the plastic seat Thenovel nylon base honing oilstone has the advantages that the abrasive stick adopts the integral casting of the plastic seat and the honing oilstones; the plastic seat is made of nylon materials provided with the characteristics of oil resistance, high temperature resistance and easy wear; moreover, the nylon materials have a certain hardness and low cost when compared with other metal materials; when in honing, the plastic seat wears together with the abrasive stick while simultaneously supporting the abrasive stick so as to enable the honing oilstone to be sufficiently used and reduce use cost; the plastic seat can not only perform guiding and scraping functions, but also protect the honing oilstone and prevent the honing oilstone from shedding, crushing, edge chipping and the like, thereby the roughness of the surface of the honing oilstone can be improved, and the inner walls of work pieces are prevented from being pulled

A decision making method for selection of finish process for a cylindrical surface

Abstract: In the present paper, fuzzy-scale-based multiple attribute decision making (MADM-TOPSIS) method has been reported to rank five different alternative finishing processes for an internal cylindrical surface through systematic multi-attribute based evaluation. The mathematical procedure yields a suitability index which is used to rank finishing processes. The present TOPSIS-MADM method indicates that the honing process is the most suitable finishing process for the internal cylindrical surfaces whereas on the other hand, the processes like ultra sonic machining and abrasive flow machining are not desirable when they are to be considered for finishing an internal cylindrical surface.

Grinding, honing, lapping

Abstract: Principles of Cutting Edge Engagement.- Structure and Composition of Grinding Sheels.- The Machinability of Various Materials.- Cooling Lubricants.- Grinding.- Honing.- Lapping and Polishing.- Special Methods.- Process Monitoring.

Hydraulic dual-feed honing head device

Abstract: The invention relates to a hydraulic dual-feed honing head which comprises a two-stage telescoping hydraulic cylinder and a honing head body, wherein the outer circumference surface of the honing head body is provided with a coarse honing emery stick seat and a microhoning emery stick seat along the circumferential direction; the two-stage telescoping hydraulic cylinder comprises a first piston rod and a second piston rod; the first piston rod is connected with a first push cone; the second piston rod is connected with a second top-chord inverted triangle mesh; the first top-chord inverted triangle mesh cooperates with the coarse honing emery stick seat; the second top-chord inverted triangle mesh cooperates with the microhoning emery stick seat; when the first top-chord inverted triangle mesh moves forwards, the coarse honing emery stick seat is driven to protrude outwards along the radial direction, thereby carrying out coarse honing; and when the second top-chord inverted triangle mesh moves towards, the microhoning emery stick seat is driven to protrude outwards, thereby carrying out microhoning.

Servo stroking method and system for producing special shapes

Abstract: A servo stroking method and system for honing wherein the cam stroking motion is controlled via combined acceleration and deceleration cam profiles to produce a finite jerk profile, a precision positioning capability for the honing element or elements, and accurate position feedback. The stroking motion is synchronized with one or more other parameters of the honing operation, such as the feed or rotational position of the honing tool, for generating non-cylindrical and special honed shapes such as tapered, barrel, and helical shapes. The cam profile can be selected for example from a simple harmonic profile, a cycloidal profile, a modified trapezoidal profile, a polynomial profile, and a modified sine profile, or a mix of cam profiles. The servo controlled stroker mechanism can include for instance a ball screw mechanism, a linear motor, a fluid cylinder, a chain drive or a belt drive.

Method for processing cam

Abstract: The invention discloses a method for processing a cam. The method comprises the following steps of: firstly, obtaining a basic contour of the cam by a casting process; and secondly, obtaining an accurate cam contour by a process of removing materials. The process of removing the material can be the integration of processes comprising coarse grinding, accurate grinding, edge rolling, honing, polishing and the like which are carried out in order. The process of rolling the edge of the cam is to make the two sides of the cam lower the middle position; and only the surface hardness of the cam can be increased but also micro reticular patterns can be formed by honing and polishing the cam. The casting process adopts chill coasting or a combination of common casting and induction quenching techniques to obtain the cam of which different parts correspond to different textures and different depths correspond to different stiffness and different textures. The method for processing the cam integrates different processing techniques, so a method for trimming the cams on a large scale is provided, and oil storage and lubrication functions of the cam surface are provided. The method for processing the cam is applicable to a valve actuating mechanism on an engine.

Bore machining method and apparatus

Abstract: A method of machining the internal bore of a hollow pipe comprises honing material from inner surface of the bore the pipe. A honing apparatus for use in the method comprises a machining tool comprising a honing head adapted for insertion into the end of a pipe to remove material from the inner surface of the pipe by abrasion.